US20220234803A1 - Formable films, laminate structures, and related methods - Google Patents
Formable films, laminate structures, and related methods Download PDFInfo
- Publication number
- US20220234803A1 US20220234803A1 US17/614,855 US202017614855A US2022234803A1 US 20220234803 A1 US20220234803 A1 US 20220234803A1 US 202017614855 A US202017614855 A US 202017614855A US 2022234803 A1 US2022234803 A1 US 2022234803A1
- Authority
- US
- United States
- Prior art keywords
- layer
- formable
- copolyesters
- pet
- multilayer film
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
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- 229910000968 Chilled casting Inorganic materials 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 241001272720 Medialuna californiensis Species 0.000 description 1
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- 239000000853 adhesive Substances 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
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- B29C66/73711—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable oriented
- B29C66/73713—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable oriented bi-axially or multi-axially
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/74—Joining plastics material to non-plastics material
- B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
- B29C66/7422—Aluminium or alloys of aluminium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/712—Containers; Packaging elements or accessories, Packages
- B29L2031/7162—Boxes, cartons, cases
- B29L2031/7164—Blister packages
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/03—3 layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/06—Coating on the layer surface on metal layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/102—Oxide or hydroxide
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/31—Heat sealable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/514—Oriented
- B32B2307/518—Oriented bi-axially
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/40—Closed containers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/70—Food packaging
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/80—Medical packaging
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2553/00—Packaging equipment or accessories not otherwise provided for
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2400/00—Presence of inorganic and organic materials
- C09J2400/10—Presence of inorganic materials
- C09J2400/16—Metal
- C09J2400/166—Metal in the pretreated surface to be joined
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2467/00—Presence of polyester
Definitions
- the present specification generally relates to laminate structures having formable films and more specifically to a blister package having a laminate structure that is heat-sealable to a lacquer layer on strain-hardened aluminum foil.
- Blister packages are well-known for packaging of food products, medicinal products, and other industrial goods.
- Blister packages are formed from laminate structures having one or more formable films.
- the laminate structures are sealed to a lid layer after the product is stored within wells formed therein.
- the lid layer is typically formed from strain-hardened aluminum foil and a sealing surface of the lid is coated with a lacquer layer for enhancing the bond between the lid layer and the laminate structure.
- the bonding performance of the lacquer layer on the sealing surface of the lid layer varies widely depending on the nature and composition of the formable films used in the laminate structure.
- an outer layer of the laminate structure may have an additional coating layer such as Vinoyl 15/45M manufactured by Wacker Polymers to improve bonding performance. But such an additional coating layer incurs increased manufacturing complexity, cost and can cause poorer performance of the blister package.
- the formable films are made of thermoplastic materials such as uncoated polyethylene terephthalate (PET), biaxially oriented Nylon (BON), polypropylene and similar materials, the laminate structures do not bond well with the lid layer.
- a multilayer film includes a first formable layer of a thermoplastic material and a sealing layer of a copolyester material.
- the sealing layer overlies the first formable layer and has an outer surface opposite the first formable layer.
- the sealing layer has a crystallinity from 5% to 20% as measured by differential scanning calorimetry (DSC) which is a technique well known to those skilled in the art.
- a blister package for packaging a product in another embodiment, includes a lid layer comprising a strain-hardened aluminum foil, a lacquer layer on a sealing surface of the strain-hardened aluminum foil and a laminate structure sealed directly to the lacquer layer.
- the laminate structure includes a multilayer film and a plurality of wells formed therethrough.
- the multilayer film includes a first formable layer of a thermoplastic material and a sealing layer of a copolyester material.
- the sealing layer overlies the first formable layer and has an outer surface opposite the first formable layer.
- the sealing layer has a crystallinity from 5% to 20% as measured by differential scanning calorimetry (DSC). The outer surface of the sealing layer is sealed directly against the lacquer layer of the foil lid.
- a method of preparing a blister package includes the step of laminating a lid layer and a multilayer laminate structure under pressure to form the blister package.
- the lid layer includes a strain-hardened aluminum foil having a lacquer layer on a sealing surface of the strain-hardened aluminum foil.
- the laminate structure includes a multilayer film having a first formable layer of a thermoplastic material and a sealing layer of a copolyester material.
- the sealing layer overlies the first formable layer and has an outer surface opposite the first formable layer.
- the sealing layer has a crystallinity from 5% to 20% as measured by differential scanning calorimetry (DSC).
- DSC differential scanning calorimetry
- FIGS. 1A, 1B, and 1C are schematic diagrams of three exemplary multilayer films having layers of formable films, according to one or more embodiments shown and described herein;
- FIG. 2 is a schematic diagram of a lamination process of forming an exemplary laminate structure with any of the exemplary multilayer films of FIGS. 1A -IC, according to one or more embodiments shown and described herein;
- FIG. 3A is a schematic diagram of a sealing process of bonding a lid layer with the exemplary laminate structure of FIG. 2 , according to one or more embodiments shown and described herein;
- FIG. 3B is a schematic diagram of forming a blister pack after sealing the exemplary laminate structure of FIG. 2 with the lid layer, according to one or more embodiments shown and described herein.
- the term “about,” when referring to a value or to an amount of mass, weight, time, volume, concentration or percentage is meant to encompass variations of in some embodiments ⁇ 20%, in some embodiments ⁇ 10%, in some embodiments ⁇ 5%, in some embodiments ⁇ 1%, in some embodiments ⁇ 0.5%, and in some embodiments ⁇ 0.1% from the specified amount, as such variations are appropriate to perform the disclosed method.
- ranges can be expressed as from “about” one particular value, and/or to “about” another particular value. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.
- Embodiments described herein are directed to a blister package having a laminate structure that is heat-sealable to a lacquer layer on a strain-hardened aluminum foil.
- the laminate structure includes a sealing layer overlying one or more layers of formable films.
- the sealing layer is made of a copolyester material and can be co-extruded with layers of formable films to form the laminate structure. Accordingly, the inventors have discovered, an additional coating layer on the outer surface of the laminate structure is not necessary for bonding the laminate structure to a lid layer of strain-hardened aluminum foil. This reduces cost and complexity in the manufacturing process while also improving the overall construction of the blister package formed from the laminate structure.
- FIGS. 1A, 1B, and 1C schematic diagrams of three exemplary multilayer films 100 having layers of formable films 120 1 are depicted.
- Each of the embodiments in FIGS. 1A-1C include a multilayer film 100 of A/B/B structure having a sealing layer 110 overlying a first formable layer 120 1 and a second formable layer 120 2 , where the first formable layer 120 1 is interposed between the sealing layer 110 and the second formable layer 120 2 .
- the embodiments shown in FIGS. 1A-1C show only two formable layers 120 1 and 120 2
- the multilayer film 100 is not restricted as such and may contain one or multiple formable layers 120 1 , 120 2 , 120 3 , 120 4 , . . . , 120 n depending on the particular application.
- the sealing layer 110 is made from a copolyester material and has a thickness from about 1.5 microns to about 4 microns.
- the material chosen for the sealing layer 110 is required to be compatible with both the material of the formable layers 120 1 , 120 2 and a multilayer extrusion process of forming the multilayer film 100 .
- the sealing layer 110 is formed from a copolyester material such as, but not limited to, copolyesters of isophthalic acid, copolyesters of ethylene glycol, copolyesters of diethylene glycol (DEG), copolyesters of triethylene glycol (TEG), copolyesters of cyclohexanedimethanol (CHDM)-modified PET, copolyesters of n-propylene glycol, and copolyesters of n-butylene glycol.
- a copolyester material such as, but not limited to, copolyesters of isophthalic acid, copolyesters of ethylene glycol, copolyesters of diethylene glycol (DEG), copolyesters of triethylene glycol (TEG), copolyesters of cyclohexanedimethanol (CHDM)-modified PET, copolyesters of n-propylene glycol, and copolyesters of n-butylene glycol
- the copolyester material is formed by a catalyzed polycondensation reaction between one or more glycol components and one or more diacid components.
- the glycol components may be ethylene glycol, DEG, TEG, CHDM, n-propylene glycol, n-butylene glycol and similar linear and branched diols.
- the diacid components may be purified terephthalic acid (PTA), commoners of adipic acid, sebacic acid, succinic acid and similar linear and branched diacids.
- the copolyester material forming the sealing layer 110 has physical properties (e.g. intrinsic viscosity) that render heat-sealable characteristics to the copolyester material and improves interfacial compatibility with the material of the formable layers 120 1 , 120 2 such that the sealing layer 110 can be co-extruded at a high temperature.
- the copolyester material has an intrinsic viscosity from about 0.5 deciliters/gram to about 1.0 deciliters/gram, preferably from about 0.6 deciliters/gram to about 0.7 deciliters/gram.
- Intrinsic viscosity (IV) of a polymer reflects the property of a polymer in solution to increase the viscosity of the solution.
- Intrinsic viscosity is defined as the ratio of the solution's specific viscosity (the relative viscosity of the polymer solution of known concentration minus one) to the concentration of the solute extrapolated to zero concentration. Thus, the intrinsic viscosity is the limiting value of the ratio of specific viscosity and concentration at zero concentration. Intrinsic viscosity can be determined by measuring the relative viscosity of the solution at several different concentrations and then extrapolating the specific viscosity at zero concentration.
- Intrinsic viscosity can also be determined by measuring the inherent viscosity at infinite dilution of the polymer, where inherent viscosity is the ratio between the natural logarithm of relative viscosity (ratio of the viscosities of the polymer solution and the pure solvent at the same temperature) and the concentration. Inherent viscosity can be measured using a method outlined in ASTM D 4603 (Standard Test Method for Determining Inherent Viscosity of Polyethylene Terephthalate (PET) by Glass Capillary Viscometer).
- the copolyester material has crystallinity from 1% to 25%, such as from 5% to 20%, from 5% to 15%, from 5% to 10%, or from 10% to 20%, for example, as measured by differential scanning calorimetry (DSC). If the copolyester material has a higher crystallinity, then it may often be heated and quenched quickly in a commercial coextrusion process such that the crystallinity is reduced to be within the range noted above.
- DSC differential scanning calorimetry
- DSC provides a known analytical technique for determining polymer crystallinity (and other morphological characteristics) based on the heat required to melt the polymer.
- the sealing layer 110 may further contain silica, alumina, or a combination thereof mixed in with the copolyester material. Dry particles of silica, alumina, or a combination thereof are blended with one or more layers of the copolyester material having low viscosity and subsequently polymerized together to form the blended sealing layer 110 .
- the sealing layer 110 has an outer surface 112 that is opposite to an inner surface 114 facing the first formable layer 120 1 .
- the outer surface 112 of the sealing layer 110 is heat-sealable directly to a lacquer layer 354 coated on a strain-hardened aluminum foil 352 (shown in FIG. 3A ).
- the sealability between the sealing layer 110 and the lacquer layer 354 can be observed starting at a temperature of about 85° C.
- one or more of the formable layers 120 1 is formed from a thermoplastic material capable of thermoforming or cold-forming such as, but not limited to, polyethylene, polypropylene, nylon, polystyrene, polyethylene terephthalate (PET), polylactic acid, and polyvinyl chloride (PVC).
- a thermoplastic material capable of thermoforming or cold-forming such as, but not limited to, polyethylene, polypropylene, nylon, polystyrene, polyethylene terephthalate (PET), polylactic acid, and polyvinyl chloride (PVC).
- one or more of the formable layers 120 1 is formed from a biaxially-oriented PET layer having a metaphase evidenced by a metaphase transition at about 180° C. to about 200° C. as measured by DSC upon a first heating and a molded volume of greater than or equal to about 200%.
- the first formable layer 120 1 may be formed from a biaxially-oriented PET layer having a metaphase evidenced by a metaphase transition at about 180° C. to about 200° C. as measured by DSC upon a first heating and a molded volume of greater than or equal to about 200%.
- the second formable layer 120 2 may be, additionally or alternatively, formed from a biaxially-oriented PET layer having a metaphase evidenced by a metaphase transition at about 180° C. to about 200° C. as measured by DSC upon a first heating and a molded volume of greater than or equal to about 200%.
- the term “metaphase” refers to an amorphous phase induced in a formable film that renders it excellent formability (e.g., thermoformability) and tensile strength, and which is not found in standard biaxially-oriented PET films.
- a metaphase can be induced and the resulting properties obtained by orienting the biaxially-oriented PET film layer at reduced temperatures and draw ratios, and subsequently allowing the biaxially-orienting PET film layer to relax to a greater extent than is done in the production of other thermoformable films.
- the metaphase is readily observed in the DSC profile of the formable films of biaxially-oriented PET as a deflection point in the heat-flow curves at approximately 180° C. to about 200° C. (e.g., 190° C.) upon first heating experiments. Being a metastable phase, second heating or annealing experiments then will not reveal this phase as the metaphase will be squelched.
- the metaphase is a quasi-stable phase intermediate in composition between that of the crystalline and amorphous materials typical of a semi-crystalline thermoplastic material.
- the phase is a tied amorphous phase associated with the crystalline structure within the film. This tied amorphous phase has additional latent elongation properties and thus allows for significantly higher formability within the formable films of biaxially-oriented PET.
- the formable films of biaxially-oriented PET can be described as having a metastable phase having a phase transition temperature less than the crystalline melting point of the film as measured by DSC.
- the phase transition temperature is about 40° C. less, about 45° C. less, about 50° C. less, about 55° C. less, about 60° C. less, or about 65° C. less than the crystalline melting point of the film as measured by DSC.
- molded volume refers to the amount of increase in the volume exhibited by a particular film layer before breakage occurs.
- molded volume is typically measured by making use of heat and reduced pressure experiments by which thin film materials are placed over a cavity mold and, under heat and reduced pressure, molded into a half-moon shape. Generally, such experimental procedures are optimized to produce the maximum molded volume before breakage occurs. The relative volume measured before breakage occurs is then normalized to a traditionally manufactured biaxially-oriented PET film that would give 100% normalized volume under optimal conditions.
- the molded volume of any well that is formed therein becomes greater than 200% due to an increase in diameter of the well.
- the increase in volume can be measured by comparing the amount of water or other liquid required to completely fill the well before and after the metaphase transition is achieved by the formable film.
- one or more of the formable layers 120 i may further include silica, alumina, or a combination thereof mixed in with the thermoplastic material.
- the first formable layer 120 1 may contain silica, alumina, or a combination thereof mixed in with the thermoplastic material.
- the second formable layer 120 2 may, additionally or alternatively, contain silica, alumina, or a combination thereof mixed in with the thermoplastic material.
- the process of blending dry particles of silica, alumina, or a combination thereof in the thermoplastic material is substantially similar to the process of blending the same within copolyester material of the sealing layer 110 , as described above.
- the one or more formable layers 120 i are prepared through the use of conventional sequential biaxial orientation machines having a single-screw mainline extrusion train and a twin-screw sub-extrusion process.
- standard PET pellets having a desired intrinsic viscosity can be fed into the main extrusion line, while pellets of another composition can be fed into a sub-extrusion process.
- a blend of standard PET pellets and silica-filled PET pellets can be fed in to the sub-extrusion process.
- the materials can then be melted separately and laminated together in a feed-block to produce a desired multilayer molten structure (e.g., an A/B/A molten structure) in an extrusion die.
- a desired multilayer molten structure e.g., an A/B/A molten structure
- the laminated PET layers emerging from the extrusion die are then quenched on a chilled casting drum to produce a thick, amorphous film structure having a thickness of about 9 ⁇ m, about 12 ⁇ m, about 15 ⁇ m, about 20 ⁇ m, about 23 ⁇ m, about 25 ⁇ m, about 30 ⁇ m, about 35 ⁇ m, about 36 ⁇ m, about 40 m, about 45 ⁇ m, or about 50 m.
- FIG. 2 is a schematic diagram of a lamination process of forming an exemplary laminate structure 200 with any of the exemplary multilayer films 100 of FIGS. 1A-1C .
- a laminate structure 200 may include multilayer film 100 laminated to a core structure.
- the core structure may include at least one layer exhibiting a metaphasic transition such as, for example, a layer of metaphasic PET.
- the core structure may include, for example, a trilayer metaphasic structure 250 .
- additional layers may be interposed between the multilayer film 100 and the core structure such as the trilayer metaphasic structure 250 .
- an intermediate layer 230 may be interposed between the multilayer film 100 and the core structure such as the trilayer metaphasic structure 250 .
- the intermediate layer 230 may be a soft metal foil such as a soft aluminum foil.
- the intermediate layer 230 may be adhered to the multilayer film 100 by a first adhesive layer 220 between the intermediate layer 230 and the multilayer film 100 .
- the intermediate layer 230 may be adhered to the core structure such as the trilayer metaphasic structure 250 , for example, by a second adhesive layer 240 between the intermediate layer 230 and the core structure. Exemplary lamination processes for forming the laminate structure 200 will now be described.
- the laminate structure 200 is formed over Lamination Step A and Lamination Step B.
- the multilayer film 100 is laminated to an intermediate layer 230 with a first adhesive layer 220 such that the first adhesive layer 220 is between the second formable layer 120 2 and the intermediate layer 230 .
- the intermediate layer 230 is formed from a soft aluminum foil.
- the first adhesive layer 220 is ADCOTE® 811A+COREACTANT F, produced by Rohm and Haas Chemicals LLC, Philadelphia, Pa. In other embodiments, adhesives based on reactions of polyols and urethane prepolymers may be used.
- a trilayer metaphasic structure 250 is laminated to the intermediate layer 230 with a second adhesive layer 240 , substantially similar to the first adhesive layer 220 , such that the second adhesive layer 240 is between the intermediate layer 230 and the trilayer metaphasic structure 250 .
- the trilayer metaphasic structure 250 has an A-B-A structure including a first PET layer 252 , a second PET layer 256 and a silica-containing PET layer 254 interposed between the first PET layer 252 and the second PET layer 256 .
- the intermediate layer 230 is placed between the second formable layer 120 2 and the first PET layer 252 .
- the first PET layer 252 and the second PET layer 256 are formed from a biaxially-oriented PET layer having a metaphase evidenced by a metaphase transition present at about 180° C. to about 200° C. as measured by DSC upon a first heating and a molded volume of greater than or equal to about 200%.
- one or more layers of thermoplastic material such as, but not limited to, polyethylene, polypropylene, nylon, polystyrene, PET, polylactic acid, and PVC may be disposed in addition to or instead of the trilayer metaphasic structure 250 .
- additional layers may be incorporated through additional lamination steps.
- the lamination process shown in FIG. 2 yields an exemplary laminate structure 200 that can be used for preparing a blister package 300 , as described below.
- FIGS. 3A-3B depict the formation of a blister package 300 from the exemplary laminate structure 200 .
- FIG. 3A depicts a schematic diagram of a sealing process of bonding a lid layer 350 with the exemplary laminate structure 200 to prepare the blister package 300
- FIG. 3B depicts a schematic diagram of forming a blister pack 360 after sealing the exemplary laminate structure 200 with the lid layer 350
- the lid layer 350 comprises the strain-hardened aluminum foil layer 352 having a sealing surface 353 . Strain-hardened aluminum foil is typically brittle and can be punctured easily to retrieve contents of the blister package 300 .
- the sealing surface 353 is coated with the lacquer layer 354 .
- the outer surface 112 of the sealing layer 110 is directly pressed against a bottom surface 355 of the lacquer layer 354 and heated to a temperature above 85° C. to form the blister package 300 . Accordingly the lid layer 350 is laminated with the multilayer laminate structure 200 under heat and pressure to form the blister package 300 .
- the laminate structure 200 rolled around an unwinder 310 is passed through a die to make a plurality of wells 320 by applying pressure, typically between 4 and 6 kg/cm 2 .
- the plurality of wells 320 are formed by a well-forming part (not shown) at a speed between about 20 to about 30 blisters per minute.
- a product 330 is then inserted in each of the plurality of wells 320 .
- the product 330 may be a food product, a medicinal product, or another commercial product.
- the lid layer 350 rolled around a spindle 340 is pressed against the laminate structure 200 and heat-sealed to form the blister package 300 , as described above. Finally, individual blister packs 360 are punched off from the blister package 300 .
- the apparatuses and methods described herein can be advantageously used for preparing a laminate structure of formable films that can be easily heat-sealable to a lid layer of strain-hardened aluminum foil to form a blister package, without requiring additional coatings for enhancing bonding between the laminate structure and the lid layer.
- additional coatings are used, the laminate structure must be processed through the laminating machine a second time to add the additional coating.
- the laminating machine need only be used once. This results in significant savings in manufacturing cost and time, while improving the overall construction of the blister package at the same time.
- Example A demonstrates the seal strength of the sealing layer in the laminate structure through experimentally-verified data.
- the seal strength of the sealing layer described in the present disclosure was examined using a first specimen of the sealing layer partially heat-sealed on one surface to a strain-hardened aluminum foil layer coated with a lacquer layer on the sealing surface and a second specimen of the sealing layer partially heat-sealed on both surfaces to strain-hardened aluminum foil layers coated with lacquer layers on the sealing surfaces.
- the test measured the force needed to separate the sealing layer from the strain-hardened aluminum foil layer(s) by gripping the unsealed portions of the strain-hardened aluminum foil layer(s) in the movable jaws of a tensile tester and then moving the jaws of the tensile tester with a constant strain rate to pull the sealed portions of the strain-hardened aluminum foil layer(s) apart.
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Composite Materials (AREA)
- Wrappers (AREA)
- Packages (AREA)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN201911021324 | 2019-05-29 | ||
IN201911021324 | 2019-05-29 | ||
PCT/IN2020/050469 WO2020240584A1 (en) | 2019-05-29 | 2020-05-26 | Formable films, laminate structures, and related methods |
Publications (1)
Publication Number | Publication Date |
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US20220234803A1 true US20220234803A1 (en) | 2022-07-28 |
Family
ID=73553594
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US17/614,855 Pending US20220234803A1 (en) | 2019-05-29 | 2020-05-26 | Formable films, laminate structures, and related methods |
Country Status (5)
Country | Link |
---|---|
US (1) | US20220234803A1 (de) |
EP (1) | EP3976721A4 (de) |
CA (1) | CA3142245A1 (de) |
MX (1) | MX2021014550A (de) |
WO (1) | WO2020240584A1 (de) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20230068772A1 (en) * | 2020-01-17 | 2023-03-02 | Sacmi Imola S.C. | Method for the production and filling of containers designed to contain food |
US11975470B2 (en) * | 2021-02-01 | 2024-05-07 | Ig Lae JO | Heat-seal-laminating PET film |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20050276525A1 (en) * | 2004-06-11 | 2005-12-15 | Sonoco Development, Inc. | Flexible packaging structure with a built-in opening and reclose feature, and method for making same |
US20110081543A1 (en) * | 2009-10-02 | 2011-04-07 | Toray Plastics (America) Inc. | Biodegradable composite barrier film |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
NL7100564A (de) * | 1970-01-26 | 1971-07-28 | ||
GB0023927D0 (en) | 2000-09-29 | 2000-11-15 | Dupont Teijin Films Us Ltd | Multilayer polymeric film |
US20040097157A1 (en) * | 2002-11-20 | 2004-05-20 | Cosentino Steven R | Thermal bondable film for insulation facing, and method for making the same |
WO2008008381A2 (en) * | 2006-07-14 | 2008-01-17 | Dupont Teijin Films U.S. Limited Partnership | Multilayer sealant film |
US10131122B2 (en) | 2015-06-18 | 2018-11-20 | Flex Films (Usa) Inc. | Formable films, laminate structures, and related methods |
-
2020
- 2020-05-26 WO PCT/IN2020/050469 patent/WO2020240584A1/en unknown
- 2020-05-26 US US17/614,855 patent/US20220234803A1/en active Pending
- 2020-05-26 MX MX2021014550A patent/MX2021014550A/es unknown
- 2020-05-26 CA CA3142245A patent/CA3142245A1/en active Pending
- 2020-05-26 EP EP20814447.7A patent/EP3976721A4/de active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050276525A1 (en) * | 2004-06-11 | 2005-12-15 | Sonoco Development, Inc. | Flexible packaging structure with a built-in opening and reclose feature, and method for making same |
US20110081543A1 (en) * | 2009-10-02 | 2011-04-07 | Toray Plastics (America) Inc. | Biodegradable composite barrier film |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20230068772A1 (en) * | 2020-01-17 | 2023-03-02 | Sacmi Imola S.C. | Method for the production and filling of containers designed to contain food |
US11975470B2 (en) * | 2021-02-01 | 2024-05-07 | Ig Lae JO | Heat-seal-laminating PET film |
Also Published As
Publication number | Publication date |
---|---|
EP3976721A4 (de) | 2022-07-06 |
CA3142245A1 (en) | 2020-12-03 |
EP3976721A1 (de) | 2022-04-06 |
WO2020240584A1 (en) | 2020-12-03 |
MX2021014550A (es) | 2022-02-11 |
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